Electrode-Lead-Integrated Electrode Assembly and Method of Manufacturing the Same

Abstract

The present invention relates to an electrode assembly including a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode, wherein an electrode tab protrudes from at least an outer periphery of one side of each of a plurality of positive electrodes and a plurality of negative electrodes, the electrode tabs being coupled to each other in tight contact in a stacking direction to constitute an electrode tab bundle, at least one through-hole is formed through the electrode tab bundle, a connection member made of an electrically conductive material is inserted through the through-hole, and an electrode lead is electrically connected to the electrode tab bundle via the connection member in a melted state, and wherein electrical connection between the electrode tab bundle and the electrode lead is achieved by heating and pressing.

1 . An electrode assembly comprising:
 a plurality of positive electrodes each having a positive electrode tab extending from an outer periphery of one side thereof;   a plurality of negative electrodes each having a negative electrode tab extending from an outer periphery of one side thereof;   a plurality of separators interposed between the positive electrodes and the negative electrodes;   a connection member made of an electrically conductive material; and   an electrode lead,   wherein the negative electrode tabs or the positive electrode tabs are coupled to each other in tight contact in a stacking direction to constitute an electrode tab bundle,   a through-hole is formed through the electrode tab bundle,   the connection member extends through the through-hole, and   the electrode lead is electrically connected to the electrode tab bundle via the connection member.   
     
     
         2 . The electrode assembly according to  claim 1 , wherein the connection member has a shape of a bar, and the connection member extends through the electrode tab bundle. 
     
     
         3 . The electrode assembly according to  claim 1 , wherein the connection member is made of a low-melting-point metal. 
     
     
         4 . The electrode assembly according to  claim 1 , wherein the electrode lead has a recess or an opening having a width approximately equal to a width of the through-hole of the electrode tab bundle, and the electrode lead is coupled to an upper surface or a lower surface of the electrode tab bundle. 
     
     
         5 . The electrode assembly according to  claim 1 , wherein the electrode lead has an opening having a width approximately equal to a width of the through-hole of the electrode tab bundle, the electrode lead is disposed within the electrode tab bundle, and the connection member extends through the opening of the electrode lead and the through-hole of the electrode tab bundle. 
     
     
         6 . The electrode assembly according to  claim 1 , wherein each of the positive electrodes and the negative electrodes comprises an electrode current collector having two metal layers coupled to each of opposite surfaces of an insulation layer. 
     
     
         7 . The electrode assembly according to  claim 6 , wherein a thickness of the insulation layer is greater than a thickness of one of the metal layers. 
     
     
         8 . The electrode assembly according to  claim 6 , wherein a density of the insulation layer is lower than a density each of the metal layers. 
     
     
         9 . The electrode assembly according to  claim 6 , wherein a melting point of the connection member is lower than a melting point of the insulation layer. 
     
     
         10 . A method of manufacturing the electrode assembly according to  claim 1 , the method comprising:
 (a) forming the through-hole in each of negative electrode tabs or the positive electrode tabs of the electrode tab bundle;   (b) stacking the negative electrode tabs or the positive electrode tabs to constitute the electrode tab bundle;   (c) stacking the electrode lead with the electrode tab bundle;   (d) inserting the connection member through the through-holes; and   (e) melting the connection member.   
     
     
         11 . The method according to  claim 10 , wherein the melting of the connection member comprises a process of heating and pressing the electrode tab bundle. 
     
     
         12 . The method according to  claim 10 , wherein, during the melting of the connection member, the electrode tab lead and the negative electrode tabs or the positive electrodes tabs constituting the electrode tab bundle are simultaneously coupled to each other. 
     
     
         13 . The method according to  claim 10 , wherein the electrode lead has a recess or an opening having a width approximately equal to a width of the through-hole formed in each of the negative electrode tabs or the positive electrode tabs of the electrode tab bundle.